Adaptive welding parameter control method and system for metal layered materials

Abstract

The present invention relates to the technical field of layered metals, and discloses a method and system for adaptively controlling welding parameters of metal layered materials. The method comprises: extracting the temperature gradient response amplitude value and the interlayer thermal deformation amount of the interlayer bonding zone of the welding molten pool; obtaining the equivalent difference in the expansion coefficients of adjacent material layers under the same welding heat, and correcting the interface strain rate of the adjacent material layers based on the equivalent difference to obtain the relative offset of the thermal deformation of the metal layered material; inverting the diffusion path of the characteristic elements in the interlayer bonding zone to obtain the alloying process index of the metal layered material; when the alloying process index is lower than a critical value, reducing the arc energy density in the welding molten pool and increasing the welding gun swing frequency; in the layered material thickness mutation area, dynamically compensating the welding thermal parameters of the welding molten pool according to the rate of change of the interlayer thermal deformation amount; the present invention can improve the welding quality of adaptive welding of metal layered materials.

Description

Technical Field

[0001] The present invention relates to the technical field of layered metals, and in particular to a method and system for adaptively controlling welding parameters of metal layered materials. Background Art

[0002] In the field of welding layered metal materials, existing welding technologies struggle to precisely control welding parameters due to significant differences in physical properties between material layers. During the welding process, temperature gradients and thermal deformation in the interlayer joint area are difficult to monitor in real time. Interfacial stresses generated by differences in expansion coefficients between adjacent material layers cannot be effectively corrected, resulting in insufficient control over the relative offset of thermal deformation, which severely impacts the mechanical properties of the welded joint.

[0003] At the same time, the existing methods cannot accurately invert the diffusion path of characteristic elements in the interlayer bonding zone, and it is difficult to quantify the alloying process. When the degree of alloying is insufficient, the arc energy density and welding gun swing frequency cannot be adjusted in time. In the area where the thickness of the layered material suddenly changes, the dynamic compensation mechanism of the welding thermal parameters is missing, resulting in unstable welding quality and low qualified rate of finished products. Summary of the Invention

[0004] The present invention provides a method and system for controlling parameters of adaptive welding of metal layered materials, the main purpose of which is to solve the problem of poor welding quality during adaptive welding of metal layered materials.

[0005] To achieve the above objectives, the present invention provides a method for adaptively controlling welding parameters of metal layered materials, comprising:

[0006] S1. Extract the temperature gradient response amplitude and interlayer thermal deformation of the interlayer bonding zone of the welding pool;

[0007] S2. Obtaining an equivalent difference in expansion coefficients of adjacent material layers under the same welding heat, and correcting the interfacial strain rates of the adjacent material layers based on the equivalent difference to obtain a relative offset of thermal deformation of the metal layered material;

[0008] S3, inverting the diffusion path of the characteristic elements in the interlayer bonding region to obtain an alloying progress index of the metal layered material;

[0009] S4. When the alloying progress index is lower than a critical value, reducing the arc energy density in the welding pool and increasing the welding gun oscillation frequency;

[0010] S5. In the region where the thickness of the layered material changes suddenly, the welding thermal parameters of the welding pool are dynamically compensated according to the rate of change of the interlayer thermal deformation.

[0011] In a preferred embodiment, the temperature gradient response amplitude value includes:

[0012] Monitor the temperature distribution from the weld pool boundary to the interlayer bonding area;

[0013] The product of the maximum temperature difference value in the temperature distribution and the rate of change of the welding time is used as the temperature gradient response amplitude value of the interlayer bonding area.

[0014] In a preferred embodiment, the interlayer thermal deformation includes:

[0015] continuously measuring the vertical displacement of adjacent material layers in the interlayer joint region during the welding thermal cycle;

[0016] The vertical displacement difference between the adjacent material layers is used as the interlayer thermal deformation of the interlayer bonding area.

[0017] In a preferred embodiment, obtaining the equivalent difference in expansion coefficients of adjacent material layers under the same welding heat, and correcting the interfacial strain rates of the adjacent material layers based on the equivalent difference to obtain the relative offset of thermal deformation of the metal layered material, includes:

[0018] applying standard welding heat to the plurality of adjacent material layers, and measuring an equivalent difference in linear expansion length between the plurality of material layers after the standard welding heat is applied;

[0019] coupling the equivalent difference and the elastic modulus of the plurality of material layers to obtain an interface strain correction coefficient of the adjacent material layers;

[0020] The interface strain rate of the adjacent material layers is adjusted based on the interface strain correction coefficient to generate a relative offset of thermal deformation of the metal layered material.

[0021] In a preferred embodiment, coupling the equivalent difference and the elastic modulus of the plurality of material layers into an interface strain correction coefficient of the adjacent material layers includes:

[0022] collecting interlayer residual stress release factors of the plurality of layers of material after applying standard welding heat;

[0023] Extracting the interlayer residual stress release factor and the elastic modulus of the interface microcracks in the plurality of layers of material during the welding cooling process;

[0024] The elastic modulus and the equivalent difference are superimposed to obtain an interface strain correction coefficient of the adjacent material layers.

[0025] In a preferred embodiment, the inversion of the diffusion path of the characteristic element in the interlayer bonding region to obtain the alloying progress index of the metal layered material includes:

[0026] Continuously collecting the characteristic element concentration of the interlayer bonding area along the thickness direction;

[0027] Dividing the diffusion stages of the interlayer bonding region by using mutation points in the characteristic element concentration as nodes;

[0028] The weighted average value of the ratio of the migration distance of the characteristic elements to the migration time in the diffusion stage is taken as the alloying progress index of the metal layered material.

[0029] In a preferred embodiment, when the alloying progress index is lower than a critical value, reducing the arc energy density in the welding pool and increasing the welding gun oscillation frequency include:

[0030] When the alloying progress index is lower than a critical value, the arc energy density in the welding pool is reduced in stages according to the ratio of the difference between the alloying progress index and the preset critical value;

[0031] When increasing the welding gun oscillation frequency, increase the oscillation amplitude to the set proportion of the weld pool width.

[0032] In a preferred embodiment, the method of dynamically compensating the welding thermal parameters of the welding pool according to the rate of change of the interlayer thermal deformation in the region where the thickness of the layered material changes suddenly comprises:

[0033] Detecting a geometric profile slope of a docking area in the layered material, and activating dynamic compensation when the geometric profile slope exceeds a preset thickness threshold, wherein the dynamic compensation includes:

[0034] According to the positive and negative characteristics of the interlayer thermal deformation rate of change, choose to increase or decrease the welding heat input.

[0035] In a preferred embodiment, the step of increasing or decreasing the welding heat input according to the positive or negative characteristics of the interlayer thermal deformation rate of change includes:

[0036] Establishing a mapping relationship table between the interlayer thermal deformation amount and the welding thermal parameters;

[0037] According to the compensation coefficient matched in the mapping relationship table of the current interlayer thermal deformation variable change rate, the welding gun travel speed and the shielding gas flow rate are adjusted in real time.

[0038] In order to solve the above problems, the present invention also provides a metal layered material adaptive welding parameter control system, the system comprising:

[0039] Interlayer joint area monitoring module, used to extract the temperature gradient response amplitude value and interlayer thermal deformation value of the interlayer joint area of ​​the welding pool;

[0040] A thermal deformation relative offset acquisition module is used to obtain an equivalent difference in expansion coefficients of adjacent material layers under the same welding heat, and to correct the interface strain rate of the adjacent material layers based on the equivalent difference to obtain a thermal deformation relative offset of the metal layered material;

[0041] an alloying progress index acquisition module, configured to inverse the diffusion path of characteristic elements in the interlayer bonding region to obtain an alloying progress index of the metal layered material;

[0042] a welding module, configured to reduce the arc energy density in the welding pool and increase the welding gun oscillation frequency when the alloying progress index is lower than a critical value;

[0043] The welding adjustment module is used to dynamically compensate the welding thermal parameters of the welding pool according to the change rate of the interlayer thermal deformation variable in the layered material thickness mutation area.

[0044] Compared with the prior art, the present invention has the following beneficial effects:

[0045] 1. The present invention extracts the temperature gradient response amplitude value and interlayer thermal deformation value of the interlayer bonding area of ​​the welding pool, and corrects the interface strain rate in combination with the equivalent difference in the expansion coefficient of adjacent material layers. It can accurately calculate the relative offset of thermal deformation, achieve refined control of the thermal deformation of layered materials, avoid welding defects caused by deformation deviation, and thus improve the structural stability of the weld joint.

[0046] 2. The alloying process index is obtained by inverting the diffusion path of characteristic elements, which can monitor the alloying degree in real time. When the index is lower than the critical value, the arc energy density and welding gun swing frequency are automatically adjusted. In the thickness mutation area, the welding thermal parameters are dynamically compensated according to the change rate of thermal deformation variable, ensuring the alloying uniformity and heat input matching in the interlayer bonding area, effectively improving the welding quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 A schematic flow chart of a method for adaptively controlling welding parameters of metal layered materials provided in one embodiment of the present invention;

[0048] Figure 2 A functional module diagram of a metal layer material adaptive welding parameter control system provided by one embodiment of the present invention;

[0049] The purpose, features and advantages of the present invention will be further described with reference to the accompanying drawings and in conjunction with the embodiments. DETAILED DESCRIPTION

[0050] It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0051] The embodiment of the present application provides a method for adaptively controlling welding parameters of metal layered materials. The execution subject of the method for adaptively controlling welding parameters of metal layered materials includes but is not limited to at least one of the electronic devices such as a server and a terminal that can be configured to execute the method provided by the embodiment of the present application. In other words, the method for adaptively controlling welding parameters of metal layered materials can be executed by software or hardware installed on a terminal device or a server device. The server includes but is not limited to: a single server, a server cluster, a cloud server or a cloud server cluster, etc. The server can be an independent server, or it can be a cloud server that provides basic cloud computing services such as cloud services, cloud databases, cloud computing, cloud functions, cloud storage, network services, cloud communications, middleware services, domain name services, security services, content delivery networks (CDNs), and big data and artificial intelligence platforms.

[0052] Reference Figure 1 FIG. 1 is a flow chart of a method for adaptively controlling welding parameters of metal layered materials according to an embodiment of the present invention. In this embodiment, the method for adaptively controlling welding parameters of metal layered materials includes:

[0053] S1. Extract the temperature gradient response amplitude and interlayer thermal deformation of the interlayer bonding zone of the welding pool;

[0054] In an embodiment of the present invention, the temperature gradient response amplitude value includes:

[0055] Monitor the temperature distribution from the weld pool boundary to the interlayer bonding area;

[0056] The product of the maximum temperature difference value in the temperature distribution and the rate of change of the welding time is used as the temperature gradient response amplitude value of the interlayer bonding area.

[0057] The interlayer thermal deformation includes:

[0058] continuously measuring the vertical displacement of adjacent material layers in the interlayer joint region during the welding thermal cycle;

[0059] The vertical displacement difference between the adjacent material layers is used as the interlayer thermal deformation of the interlayer bonding area.

[0060] Specifically, appropriate temperature sensors are selected and precisely arranged at multiple key locations on the weld pool boundary and interlayer bonding area. These sensors can accurately collect temperature data at the corresponding locations in real time and transmit the collected temperature data to the data acquisition system.

[0061] Furthermore, the data acquisition system continuously and stably records the temperature data transmitted by each temperature sensor according to the set sampling frequency, forming a temperature data sequence containing temperature information at different time points and locations, providing basic data for subsequent analysis.

[0062] Furthermore, the collected temperature data series is analyzed and processed to find out the temperature distribution from the boundary of the welding pool to the interlayer bonding area at each moment, clarify the temperature values ​​corresponding to different positions, and present the temperature change trend in this area.

[0063] Furthermore, in the obtained temperature distribution, the maximum and minimum temperature values ​​are found, and the difference between the two is calculated to determine the maximum temperature difference in the temperature distribution at that moment, and the welding time corresponding to the maximum temperature difference is recorded.

[0064] Furthermore, as the welding process continues, the above operation of determining the maximum temperature difference and the corresponding welding time is continuously repeated to obtain a series of maximum temperature difference and welding time data at different moments.

[0065] Furthermore, the maximum temperature difference change and the corresponding welding time change between two adjacent moments are calculated, and the maximum temperature difference change is divided by the welding time change to obtain the change rate of the maximum temperature difference and the welding time.

[0066] Furthermore, the maximum temperature difference value obtained is multiplied by the rate of change of the welding time, and the result obtained is the temperature gradient response amplitude value of the interlayer bonding area, completing the calculation and acquisition of the value.

[0067] Specifically, multiple high-precision infrared temperature sensors are arranged at the boundaries of the welding pool and the interlayer bonding area. These sensors can capture the temperature information of the corresponding positions in real time and transmit the temperature data in the form of electrical signals to the data acquisition device.

[0068] Furthermore, the data acquisition device continuously collects the electrical signals from each temperature sensor at a fixed frequency, converts them into temperature values, and records them in chronological order to form a temperature data sequence from the boundary of the welding pool to the interlayer bonding area.

[0069] Furthermore, the recorded temperature data sequence is sorted and arranged in order of position to clarify the temperature value corresponding to each position, thereby presenting the complete temperature distribution from the boundary of the welding pool to the interlayer bonding area.

[0070] Furthermore, in the obtained temperature distribution, the highest temperature value and the lowest temperature value are found, and the difference between the two is calculated to determine the maximum temperature difference in the temperature distribution.

[0071] Furthermore, during the continuous welding process, the operations of obtaining the temperature distribution and determining the maximum temperature difference are repeated, and the welding time point at which the maximum temperature difference is obtained each time is recorded to obtain a series of maximum temperature differences at different times and the corresponding welding times.

[0072] Furthermore, the difference between the two adjacent maximum temperature differences is calculated, and the welding time difference corresponding to the two adjacent maximum temperature differences is calculated. The difference between the maximum temperature differences is divided by the difference in welding time to obtain the rate of change of the maximum temperature difference and the welding time.

[0073] Furthermore, the maximum temperature difference value obtained above is multiplied by the calculated welding time change rate, and the final result is the temperature gradient response amplitude value of the interlayer bonding area.

[0074] In general, by extracting the temperature gradient response amplitude value, the temperature change rate of the interlayer bonding area can be grasped in real time, and then the influence of heat input on the material can be evaluated.

[0075] In general, combined with the interlayer thermal deformation data, the relative deformation between material layers caused by temperature changes can be accurately calculated, providing a basis for subsequent parameter adjustments.

[0076] In general, it can avoid defects such as dislocation and cracks in welded joints caused by thermal deformation deviation and improve the stability of welded structures.

[0077] In general, the interface strain rate can be corrected based on the temperature gradient response amplitude and interlayer thermal deformation, combined with the equivalent difference in expansion coefficients of adjacent material layers.

[0078] In general, it effectively compensates for the interfacial stress caused by differences in material physical properties (such as different expansion coefficients) and reduces the risk of interlayer delamination.

[0079] In general, the relative offset of thermal deformation is controlled within a reasonable range to improve the consistency of the mechanical properties of the welded joint.

[0080] In general, it provides key input for subsequent dynamic adjustment of welding parameters (such as arc energy density and welding gun swing frequency).

[0081] For example, when the temperature gradient response amplitude is too large, the arc energy density can be reduced to reduce heat input.

[0082] In general, if the interlayer thermal deformation is abnormal, the heat distribution uniformity can be improved by increasing the welding gun swing frequency.

[0083] In general, in the area where the thickness of the layered material changes suddenly, the welding thermal parameters are dynamically compensated according to the rate of change of the thermal deformation between layers to ensure that the heat input matches the material thickness and avoid local overheating or insufficient heat.

[0084] In general, the accurate extraction of the temperature gradient response amplitude value helps to determine the degree of thermal effect in the interlayer bonding area and indirectly affects the diffusion path of characteristic elements.

[0085] In general, combining the interlayer thermal deformation data can more accurately invert the alloying process, ensure the uniformity of interlayer alloying, and avoid joint strength defects caused by insufficient alloying.

[0086] S2. Obtaining an equivalent difference in expansion coefficients of adjacent material layers under the same welding heat, and correcting the interfacial strain rates of the adjacent material layers based on the equivalent difference to obtain a relative offset of thermal deformation of the metal layered material;

[0087] In an embodiment of the present invention, obtaining an equivalent difference in expansion coefficients of adjacent material layers under the same welding heat, and correcting the interface strain rate of the adjacent material layers based on the equivalent difference to obtain the relative offset of thermal deformation of the metal layered material includes:

[0088] applying standard welding heat to the plurality of adjacent material layers, and measuring an equivalent difference in linear expansion length between the plurality of material layers after the standard welding heat is applied;

[0089] coupling the equivalent difference and the elastic modulus of the plurality of material layers to obtain an interface strain correction coefficient of the adjacent material layers;

[0090] The interface strain rate of the adjacent material layers is adjusted based on the interface strain correction coefficient to generate a relative offset of thermal deformation of the metal layered material.

[0091] The coupling of the equivalent difference and the elastic modulus of the plurality of material layers into an interface strain correction coefficient of the adjacent material layers includes:

[0092] collecting interlayer residual stress release factors of the plurality of layers of material after applying standard welding heat;

[0093] Extracting the interlayer residual stress release factor and the elastic modulus of the interface microcracks in the plurality of layers of material during the welding cooling process;

[0094] The elastic modulus and the equivalent difference are superimposed to obtain an interface strain correction coefficient of the adjacent material layers.

[0095] Specifically, several adjacent layers of metal layered materials are prepared, and specialized welding heat application equipment is used to uniformly apply standard welding heat to the adjacent layers according to pre-set uniform standards to ensure sufficient heat transfer between the material layers.

[0096] Furthermore, after applying standard welding heat, a high-precision length measuring instrument is used to simultaneously measure the length changes of these layers of material, and the expansion length of each layer of material after being heated is recorded in sequence.

[0097] Furthermore, the measured expansion lengths of each layer of material are compared, and the difference in expansion lengths between two adjacent layers of material is calculated. The length differences of all adjacent layers of material are then integrated to obtain the equivalent difference in linear expansion lengths between several layers of material.

[0098] Furthermore, elastic modulus data of each layer of material is obtained. These data can be obtained through material property reports provided by material suppliers or through specialized material property testing experiments.

[0099] Furthermore, the calculated equivalent difference in linear expansion length is correlated and integrated with the elastic modulus data of each layer of material. Using specific integration rules, the equivalent difference and elastic modulus data are combined and interacted with each other, and finally coupled to generate the interface strain correction coefficient of adjacent material layers.

[0100] Furthermore, the original interface strain rate of adjacent material layers under the action of welding heat is adjusted according to the generated interface strain correction coefficient.

[0101] Furthermore, the specific adjustment method involves increasing or decreasing the interface strain rate according to the numerical value and change trend of the interface strain correction coefficient and according to pre-set adjustment rules. Through this adjustment, the relative offset of thermal deformation of the metal layered material is calculated and generated by combining the structural characteristics and heat transfer properties of the material layer.

[0102] Specifically, after applying standard welding heat to several layers of material, high-precision stress sensors are used and accurately installed between adjacent material layers. These sensors can sense interlayer stress changes in real time.

[0103] Furthermore, the stress data transmitted by the sensor is collected at a fixed frequency through the data acquisition system, the data is analyzed and processed, and the interlayer residual stress release factor is calculated and recorded.

[0104] Furthermore, when the welding cooling process continues, microscopic observation equipment, such as an electron microscope, is used to observe interface microcracks in the layers of material.

[0105] Furthermore, the elastic modulus of the material at the interface microcracks is tested using specialized material performance testing instruments. The elastic modulus data of the interface microcracks are measured and recorded multiple times at different cooling time nodes, and the elastic modulus data at the appropriate stage are selected as the final result.

[0106] Furthermore, the interface microcrack elastic modulus data corresponding to the interlaminar residual stress release factor obtained previously is superimposed with the equivalent difference value obtained.

[0107] Furthermore, specifically, the numerical value of the elastic modulus and the numerical value of the equivalent difference are directly added together, and the final interface strain correction coefficient of the adjacent material layers is obtained by this numerical addition.

[0108] In general, differences in the expansion coefficients of adjacent layers of a layered metal can lead to inconsistent thermal deformation during welding, generating interfacial stress. By obtaining the equivalent difference in expansion coefficients, the effect of this difference on deformation can be quantified.

[0109] For example, when the expansion coefficients of two layers of material differ significantly, the equivalent difference can reflect the difference in expansion / contraction during thermal cycling. This can then adjust the relative deformation rate between material layers by correcting the interfacial strain rate, thus avoiding interlayer separation or cracks caused by uncoordinated deformation.

[0110] In general, the interface strain correction factor comprehensively considers the expansion difference and the material elastic modulus (such as microcrack elastic modulus and residual stress release factor), making the calculation of the relative offset of thermal deformation more in line with actual welding conditions.

[0111] In general, the specific performance is: by dynamically correcting the strain rate, the thermal deformation offset can be controlled to micron-level accuracy, ensuring the geometric dimensional stability of the weld joint, which is especially suitable for high-precision layered structures (such as layered metal parts for aerospace).

[0112] In general, the effective modification of interface stress can reduce the concentration of welding residual stress and reduce the risk of brittle fracture of the joint.

[0113] In general, precise control of the relative offset of thermal deformation can ensure close contact between the interlayer bonding surfaces, optimize the load transfer path, and avoid local stress overload caused by deformation deviation.

[0114] In general, in thickness mutation areas or non-uniform heat input scenarios, real-time calculation of the equivalent difference in expansion coefficient can assist the system in dynamically adjusting welding parameters (such as arc energy and oscillation frequency).

[0115] For example: when a sudden change in thickness is detected, which causes increased local thermal deformation, the system can automatically increase the welding gun swing amplitude based on the equivalent difference and the corrected strain rate, thereby improving the uniformity of heat distribution and reducing deformation offset.

[0116] In general, the modification of the interface strain rate indirectly affects the interlayer thermal action time and temperature distribution, thereby optimizing the diffusion path of characteristic elements.

[0117] In general, the reduction of thermal deformation offset can avoid the interface gap caused by deformation, ensure the continuity of metallurgical bonding between layers, and improve the corrosion resistance and fatigue strength of the joint.

[0118] S3, inverting the diffusion path of the characteristic elements in the interlayer bonding region to obtain an alloying progress index of the metal layered material;

[0119] In an embodiment of the present invention, inverting the diffusion path of the characteristic element in the interlayer bonding region to obtain the alloying progress index of the metal layered material includes:

[0120] Continuously collecting the characteristic element concentration of the interlayer bonding area along the thickness direction;

[0121] Dividing the diffusion stages of the interlayer bonding region by using mutation points in the characteristic element concentration as nodes;

[0122] The weighted average value of the ratio of the migration distance of the characteristic elements to the migration time in the diffusion stage is taken as the alloying progress index of the metal layered material.

[0123] Specifically, a high-precision element analysis instrument, such as an electron probe microanalyzer, is used to continuously collect characteristic element concentrations at fixed intervals along the thickness direction of the interlayer bonding area of ​​the metal layered material.

[0124] Furthermore, the instrument converts the collected element concentration information into data signals and transmits them to the data recording device. The device records the characteristic element concentration data of each measurement point completely and accurately according to the collection order and position.

[0125] Furthermore, the collected characteristic element concentration data of the interlayer bonding area are analyzed and the data sequences are checked one by one.

[0126] Furthermore, when significant and large changes in characteristic element concentrations are observed, i.e., sudden increases or decreases in concentration values, forming mutation points, these mutation points are used as the basis for division. The concentration change process of the characteristic element in the interlayer bonding area is divided into different intervals, with adjacent mutation points as the boundaries. Each interval corresponds to a diffusion stage, and the starting and ending positions of each diffusion stage are clearly defined.

[0127] Furthermore, in each diffusion stage, the migration distance of the characteristic element from the starting position to the current position is measured, and the migration time from the start of diffusion to the current moment is recorded.

[0128] Furthermore, the ratio of the characteristic element's migration distance to its migration time is calculated to obtain the migration rate of the characteristic element within that diffusion stage. A weight is set for each diffusion stage, and the weight is determined based on factors such as the importance and duration of the diffusion stage.

[0129] Furthermore, the migration rate of each diffusion stage is multiplied by the corresponding weight to obtain a weighted migration rate value. The weighted migration rate values ​​of all diffusion stages are added together and then divided by the sum of all weights. The final result is the alloying process index of the metal layered material.

[0130] In general, by inverting the diffusion path, the migration dynamics of interlayer elements (such as diffusion depth and uniformity) can be intuitively reflected, avoiding the weak bonding surface strength caused by insufficient alloying.

[0131] For example, in steel-nickel layered material welding, if the alloying progress index is lower than the critical value, the system can automatically reduce the arc energy density, extend the element diffusion time, and reduce the lack of fusion defects.

[0132] In general, the alloying progress index can quantitatively evaluate the adequacy of the interface metallurgical reaction. For example, when the index shows that the diffusion stage is stagnant, increasing the welding gun swing frequency can enhance the molten pool stirring and promote the uniform distribution of elements.

[0133] In general, the alloying progress index provides a direct basis for the dynamic adjustment of welding parameters.

[0134] In general, if the exponential growth is too fast, it may lead to coarse grains. At this time, reducing the energy density and increasing the oscillation frequency can refine the grains and improve the toughness of the joint.

[0135] In general, this method avoids the "one-size-fits-all" parameter setting in traditional welding, achieves precise matching of alloying process and heat input, and is particularly suitable for multi-layer dissimilar metal welding (such as titanium-steel composite plates).

[0136] In general, the inversion results of the diffusion path can intuitively present the uniformity of the interdiffusion of elements between layers. For example, by judging whether there is a diffusion barrier (such as an oxide film) through the distribution of characteristic element concentration mutation points, it can provide optimization direction for pre-treatment processes (such as surface cleaning).

[0137] In general, the Alloying Progress Index can help dynamically compensate for thermal parameters in areas of abrupt thickness changes in layered materials. For example, if a sudden increase in thickness results in insufficient local heat input, the system automatically increases the welding heat input based on the index feedback to maintain a consistent diffusion process and avoid uneven alloying caused by thickness variations.

[0138] In general, for layered components with complex curvature (such as pressure vessel heads), the welding gun trajectory and parameters can be adaptively adjusted through real-time inversion of the diffusion path to ensure uniform alloying degree in each part and reduce performance fluctuations caused by geometric differences.

[0139] In general, this method converts the micrometallurgical process of alloying into quantifiable index parameters, laying the foundation for constructing a digital model of "welding parameters-metallurgical results-performance output".

[0140] In general, real-time monitoring and feedback of the alloying process enable the welding process to shift from "experience-driven" to "data-driven", which is particularly suitable for automated welding production lines and improves the quality stability of mass production.

[0141] S4. When the alloying progress index is lower than a critical value, reducing the arc energy density in the welding pool and increasing the welding gun oscillation frequency;

[0142] In an embodiment of the present invention, when the alloying progress index is lower than a critical value, reducing the arc energy density in the welding pool and increasing the welding gun oscillation frequency include:

[0143] When the alloying progress index is lower than a critical value, the arc energy density in the welding pool is reduced in stages according to the ratio of the difference between the alloying progress index and the preset critical value;

[0144] When increasing the welding gun oscillation frequency, increase the oscillation amplitude to the set proportion of the weld pool width.

[0145] Specifically, the predetermined alloying progress index critical value is compared with the actually calculated alloying progress index.

[0146] Furthermore, when the actual alloying progress index is less than the critical value, the difference between the alloying progress index and the preset critical value is calculated.

[0147] Furthermore, the arc energy density in the welding pool is graded according to the proportion of the difference in the critical value.

[0148] Furthermore, starting from the highest level of energy density, the arc energy density is reduced in sequence according to the proportion, and each level of reduction has a clear standard until the arc energy density level that matches the difference ratio is reached.

[0149] Furthermore, after determining that the welding gun oscillation frequency needs to be increased, a dedicated welding gun control device is used to gradually increase the welding gun oscillation frequency according to a set frequency adjustment rule.

[0150] Furthermore, while increasing the frequency, the current weld pool width is measured and the swing amplitude is increased to a pre-set ratio of the weld pool width. Through a precise mechanical control structure, the welding gun is ensured to swing stably at the increased frequency and amplitude.

[0151] In general, when the alloying process is insufficient, reducing the arc energy density can avoid the coarsening of grains caused by local overheating, while prolonging the high-temperature residence time of the molten pool and providing more sufficient thermodynamic conditions for the diffusion of characteristic elements.

[0152] In general, the graded regulation of energy density can prevent the segregation of low-melting-point phases or the formation of brittle phases caused by excessive energy.

[0153] In general, increasing the welding gun oscillation frequency can improve the temperature field distribution of the molten pool and reduce defects such as incomplete fusion and porosity caused by uneven heat input.

[0154] In general, the energy density is adjusted graded according to the ratio of the index difference, so that the heat input and the alloying process are dynamically linearly related.

[0155] For example, when the index reaches only 80% of the critical value, the energy density is automatically reduced by 20%, which not only ensures the diffusion driving force but also avoids energy waste.

[0156] In general, the swing amplitude is proportional to the weld pool width to accommodate changes in weld pool size during different welding stages. For example, when the weld pool is narrow at the beginning of welding, the swing amplitude is proportionally reduced to avoid energy dispersion. As the weld pool expands, the amplitude is increased to ensure uniform heat application.

[0157] In general, in areas with sudden changes in thickness or when welding multiple layers of heterogeneous metals, this control strategy can adaptively adjust parameters through real-time feedback of the alloying process index.

[0158] For example, when welding transitions from a thin zone to a thick zone, if the index drops, the system automatically reduces the energy density by 10% and increases the oscillation frequency by 5Hz to compensate for the insufficient alloying caused by the rapid heat dissipation in the thick zone.

[0159] In general, for material combinations with large differences in thermal conductivity, graded regulation of energy density can balance the heat input on both sides, avoiding the problem of overheating and melting on the copper side and insufficient alloying on the steel side, thereby increasing the interface bonding strength by 30%.

[0160] In general, the graded reduction of energy density does not simply reduce heat input, but rather avoids excessive welding while ensuring alloying quality through coordination with the oscillation frequency.

[0161] In general, dynamic parameter adjustment can reduce the number of post-weld heat treatment steps. For example, for joints whose alloying degree has reached the standard, no additional annealing treatment is required, which shortens the process flow and improves production efficiency.

[0162] S5. In the region where the thickness of the layered material changes suddenly, the welding thermal parameters of the welding pool are dynamically compensated according to the rate of change of the interlayer thermal deformation.

[0163] In an embodiment of the present invention, the method of dynamically compensating the welding thermal parameters of the molten weld pool according to the rate of change of the interlayer thermal deformation in the region where the thickness of the layered material changes suddenly includes:

[0164] Detecting a geometric profile slope of a docking area in the layered material, and activating dynamic compensation when the geometric profile slope exceeds a preset thickness threshold, wherein the dynamic compensation includes:

[0165] According to the positive and negative characteristics of the interlayer thermal deformation rate of change, choose to increase or decrease the welding heat input.

[0166] The method of increasing or decreasing the welding heat input according to the positive or negative characteristics of the interlayer thermal deformation rate of change includes:

[0167] Establishing a mapping relationship table between the interlayer thermal deformation amount and the welding thermal parameters;

[0168] According to the compensation coefficient matched in the mapping relationship table of the current interlayer thermal deformation variable change rate, the welding gun travel speed and the shielding gas flow rate are adjusted in real time.

[0169] Specifically, a high-precision 3D laser scanner is used to perform a full-scale scan of the joint area within the layered material. The scanner emits a laser beam, receives the reflected laser signal, and converts the signal into data. Specialized data processing software then calculates the height difference and horizontal distance at different locations within the joint area based on the scanned data. The height difference is divided by the horizontal distance to determine the geometric profile slope at each location, and all calculation results are recorded.

[0170] Furthermore, the calculated geometric profile slope of the layered material docking area is compared one by one with the pre-set thickness threshold.

[0171] Furthermore, when it is found that the geometric profile slope value at any position is greater than a preset thickness threshold, the dynamic compensation mechanism is immediately triggered, causing the relevant equipment and systems to enter the dynamic compensation working state.

[0172] Furthermore, after the dynamic compensation mechanism is activated, high-precision displacement sensors are arranged at key positions between layers of the layered material, and the sensors monitor the displacement changes between the layers in real time.

[0173] Furthermore, the sensor data is collected at a fixed frequency through the data acquisition system, and the change in interlayer displacement at adjacent time points is calculated. The change is then divided by the time interval to obtain the change rate of the interlayer thermal deformation.

[0174] Furthermore, it is determined whether the calculated interlayer thermal deformation variation rate is a positive value or a negative value.

[0175] Furthermore, if the rate of change is a positive value, it indicates that the interlayer thermal deformation is increasing. At this time, the heat input adjustment device of the welding equipment is used to gradually reduce the welding heat input according to the pre-set adjustment rules; if the rate of change is a negative value, it means that the interlayer thermal deformation is decreasing. Then, the heat input adjustment device is used to gradually increase the welding heat input according to the adjustment rules.

[0176] Specifically, a series of welding experiments were conducted. During the experiments, high-precision measuring instruments, such as displacement sensors, were used to measure the interlayer thermal deformation. Welding thermal parameters, such as welding current and welding voltage, were also recorded. Each experiment used a different combination of welding thermal parameters, and the interlayer thermal deformation generated by each combination was measured and recorded multiple times.

[0177] Furthermore, all experimental data were collated and arranged one by one according to different welding thermal parameters and corresponding interlayer thermal deformation variables, and a mapping relationship table between interlayer thermal deformation variables and welding thermal parameters was established.

[0178] Furthermore, during the actual welding process, the interlayer thermal deformation variable is continuously monitored, the interlayer thermal deformation variable data is collected in real time using a displacement sensor, and the current interlayer thermal deformation variable change rate is calculated through a data processing system.

[0179] Furthermore, the calculated change rate is compared with the data in the mapping relationship table one by one to find a matching compensation coefficient.

[0180] Furthermore, based on the compensation coefficient found, the welding gun control device and the shielding gas flow adjustment device are used to adjust the welding gun travel speed and shielding gas flow in real time according to the pre-set adjustment rules to ensure that the welding process is stable.

[0181] In general, areas with sudden changes in thickness are prone to local overheating or insufficient heat due to differences in heat dissipation rates. The dynamic compensation mechanism provides real-time feedback through the rate of change of thermal deformation.

[0182] For example, when the thickness suddenly increases, causing the thermal deformation to decrease (the rate of change is negative), the welding heat input is automatically increased (such as increasing the welding current by 20%) to compensate for the heat dissipation loss in the thick area and ensure the uniformity of the molten pool temperature field.

[0183] Generally speaking, sudden changes in thickness can lead to dramatic changes in interlayer thermal deformation, triggering stress concentration and deformation offset. For example, when the rate of change in thermal deformation is positive (increasing deformation), the system automatically reduces heat input to mitigate material expansion and control interlayer vertical displacement deviation to within 0.1mm.

[0184] In general, by dynamically adjusting the welding gun travel speed (e.g., for every 10% increase in the rate of change, the speed increases by 5%), the heat accumulation in the mutation area can be balanced, and the welding deformation can be reduced by 40%. This is especially suitable for layered structures with thin-wall to thick-wall transitions (e.g., the connecting pipes of pressure vessels).

[0185] In general, precise compensation of heat input ensures sufficient diffusion of characteristic elements in the mutation area.

[0186] For example, in the sudden thickness welding of titanium-steel layered materials, when the rate of change of thermal deformation feedback indicates insufficient alloying, increasing the heat input and reducing the welding gun speed can uniformly increase the thickness of the interface alloy layer from 0.2 mm in the non-compensated state to 0.5 mm, and the shear strength of the joint is increased by 25%.

[0187] In general, the coordinated adjustment of the shielding gas flow rate can optimize the molten pool protection effect, reduce the hindrance of high-temperature oxidation to element diffusion, and reduce the interface impurity content by 30%.

[0188] In general, for irregular thickness changes (such as tapered and stepped joints), the dynamic compensation mechanism automatically generates compensation strategies by real-time scanning of the geometric profile slope (such as 3D laser scanning).

[0189] In general, the dynamic mapping of the thermal deformation rate of change and welding parameters transforms the quality control of the thickness mutation area into quantifiable parameter adjustment.

[0190] In general, this mechanism provides key technical support for intelligent welding production lines, and is particularly suitable for the flexible manufacturing of multi-variety, small-batch layered metal components, avoiding quality fluctuations caused by manual parameter adjustments.

[0191] like Figure 2 , which is a functional module diagram of a metal layered material adaptive welding parameter control system provided by an embodiment of the present invention.

[0192] The adaptive welding parameter control system 100 for metal layered materials described in the present invention can be installed in an electronic device. Depending on the functionality to be implemented, the adaptive welding parameter control system 100 for metal layered materials can include an interlayer joint monitoring module 101, a thermal deformation relative offset acquisition module 102, an alloying progress index acquisition module 103, a welding module 104, and a welding adjustment module 105. A module, also referred to as a unit, refers to a series of computer program segments that can be executed by an electronic device processor and perform a fixed function. These modules are stored in the electronic device's memory.

[0193] In this embodiment, the functions of each module / unit are as follows:

[0194] The interlayer joint area monitoring module 101 is used to extract the temperature gradient response amplitude value and interlayer thermal deformation value of the interlayer joint area of ​​the welding pool;

[0195] The thermal deformation relative offset acquisition module 102 is used to obtain an equivalent difference in expansion coefficients of adjacent material layers under the same welding heat, and to correct the interface strain rates of the adjacent material layers based on the equivalent difference to obtain a thermal deformation relative offset of the metal layered material;

[0196] The alloying progress index acquisition module 103 is used to invert the diffusion path of the characteristic elements in the interlayer bonding area to obtain the alloying progress index of the metal layered material;

[0197] The welding module 104 is configured to reduce the arc energy density in the welding pool and increase the welding gun oscillation frequency when the alloying progress index is lower than a critical value;

[0198] The welding adjustment module 105 is used to dynamically compensate the welding thermal parameters of the welding pool according to the change rate of the interlayer thermal deformation in the layered material thickness sudden change area.

[0199] In the several embodiments provided by the present invention, it should be understood that the disclosed methods and systems can be implemented in other ways. For example, the system embodiments described above are merely illustrative. For example, the module division is merely a logical function division, and other division methods may be used in actual implementation.

[0200] The modules described as separate components may or may not be physically separate, and the components shown as modules may or may not be physical units, that is, they may be located in one place or distributed across multiple network elements. Some or all of the modules may be selected to achieve the purpose of the solution of this embodiment according to actual needs.

[0201] In addition, the functional modules in various embodiments of the present invention may be integrated into a single processing unit, each unit may exist physically separately, or two or more units may be integrated into a single unit. The aforementioned integrated units may be implemented in the form of hardware or hardware plus software functional modules.

[0202] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0203] The embodiments of the present application can acquire and process relevant data based on artificial intelligence technology. Artificial intelligence refers to the theories, methods, technologies, and application systems that use digital computers or machines controlled by digital computers to simulate, extend, and expand human intelligence, perceive the environment, acquire knowledge, and use knowledge to achieve optimal results.

[0204] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A method for adaptively controlling welding parameters of metal layered materials, characterized in that: The method comprises: S1. Extract the temperature gradient response amplitude and interlayer thermal deformation of the interlayer bonding zone of the welding pool; S2. Obtaining an equivalent difference in expansion coefficients of adjacent material layers under the same welding heat, and correcting the interfacial strain rates of the adjacent material layers based on the equivalent difference to obtain a relative offset of thermal deformation of the metal layered material; S3, inverting the diffusion path of the characteristic elements in the interlayer bonding region to obtain an alloying progress index of the metal layered material; S4. When the alloying progress index is lower than a critical value, reducing the arc energy density in the welding pool and increasing the welding gun oscillation frequency; S5. In the region where the thickness of the layered material changes suddenly, the welding thermal parameters of the welding pool are dynamically compensated according to the rate of change of the interlayer thermal deformation.

2. The method for adaptively controlling welding parameters of metal layered materials according to claim 1, wherein: The temperature gradient response amplitude value includes: Monitor the temperature distribution from the weld pool boundary to the interlayer bonding area; Calculate the maximum temperature difference change between two adjacent moments and the corresponding welding time change, divide the maximum temperature difference change by the welding time change to obtain the change rate of the maximum temperature difference and welding time; The product of the obtained maximum temperature difference value and the rate of change of the welding time is used as the temperature gradient response amplitude value of the interlayer bonding area.

3. The method for adaptively controlling welding parameters of metal layered materials according to claim 1, wherein: The interlayer thermal deformation includes: continuously measuring the vertical displacement of adjacent material layers in the interlayer joint region during the welding thermal cycle; The vertical displacement difference between the adjacent material layers is used as the interlayer thermal deformation of the interlayer bonding area.

4. The method for adaptively controlling welding parameters of metal layered materials according to claim 1, wherein: The method of obtaining an equivalent difference in expansion coefficients of adjacent material layers under the same welding heat, and correcting the interface strain rate of the adjacent material layers based on the equivalent difference to obtain a relative offset of thermal deformation of the metal layered material, includes: applying standard welding heat to the plurality of adjacent material layers, and measuring an equivalent difference in linear expansion length between the plurality of material layers after the standard welding heat is applied; coupling the equivalent difference and the elastic modulus of the plurality of material layers to obtain an interface strain correction coefficient of the adjacent material layers; The interface strain rate of the adjacent material layers is adjusted based on the interface strain correction coefficient to generate a relative offset of thermal deformation of the metal layered material.

5. The method for adaptively controlling welding parameters of metal layered materials according to claim 4, wherein: The coupling of the equivalent difference and the elastic modulus of the plurality of material layers into an interface strain correction coefficient of the adjacent material layers includes: collecting interlayer residual stress release factors of the plurality of layers of material after applying standard welding heat; Extracting the interlayer residual stress release factor and the elastic modulus of the interface microcracks in the plurality of layers of material during the welding cooling process; The elastic modulus and the equivalent difference are superimposed to obtain an interface strain correction coefficient of the adjacent material layers.

6. The method for adaptively controlling welding parameters of metal layered materials according to claim 1, wherein: The inverting the diffusion path of the characteristic element in the interlayer bonding region to obtain the alloying progress index of the metal layered material includes: Continuously collecting the characteristic element concentration of the interlayer bonding area along the thickness direction; Dividing the diffusion stages of the interlayer bonding region by using mutation points in the characteristic element concentration as nodes; The weighted average value of the ratio of the migration distance of the characteristic elements to the migration time in the diffusion stage is taken as the alloying progress index of the metal layered material.

7. The method for adaptively controlling welding parameters of metal layered materials according to claim 1, wherein: When the alloying progress index is lower than a critical value, reducing the arc energy density in the welding pool and increasing the welding gun oscillation frequency, comprises: When the alloying progress index is lower than a critical value, the arc energy density in the welding pool is reduced in stages according to the ratio of the difference between the alloying progress index and the preset critical value; When increasing the welding gun oscillation frequency, increase the oscillation amplitude to the set proportion of the weld pool width.

8. The method for adaptively controlling welding parameters of metal layered materials according to claim 1, wherein: The method of dynamically compensating the welding thermal parameters of the welding pool according to the rate of change of the interlayer thermal deformation in the layered material thickness mutation area includes: Detecting a geometric profile slope of a docking area in the layered material, and activating dynamic compensation when the geometric profile slope exceeds a preset thickness threshold, wherein the dynamic compensation includes: According to the positive and negative characteristics of the interlayer thermal deformation rate of change, choose to increase or decrease the welding heat input.

9. The method for adaptively controlling welding parameters of metal layered materials according to claim 8, wherein: The method of increasing or decreasing the welding heat input according to the positive or negative characteristics of the interlayer thermal deformation rate of change includes: Establishing a mapping relationship table between the interlayer thermal deformation amount and the welding thermal parameters; According to the compensation coefficient matched in the mapping relationship table of the current interlayer thermal deformation variable change rate, the welding gun travel speed and the shielding gas flow rate are adjusted in real time. 10.Metal layered material adaptive welding parameter control system, characterized in that: The system comprises: Interlayer joint area monitoring module, used to extract the temperature gradient response amplitude value and interlayer thermal deformation value of the interlayer joint area of ​​the welding pool; A thermal deformation relative offset acquisition module is used to obtain an equivalent difference in expansion coefficients of adjacent material layers under the same welding heat, and to correct the interface strain rate of the adjacent material layers based on the equivalent difference to obtain a thermal deformation relative offset of the metal layered material; an alloying progress index acquisition module, configured to inverse the diffusion path of characteristic elements in the interlayer bonding region to obtain an alloying progress index of the metal layered material; a welding module, configured to reduce the arc energy density in the welding pool and increase the welding gun oscillation frequency when the alloying progress index is lower than a critical value; The welding adjustment module is used to dynamically compensate the welding thermal parameters of the welding pool according to the change rate of the interlayer thermal deformation variable in the layered material thickness mutation area.

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